Complete Details Inside - Conference Proceedings · Dense Medium Cyclones ... FLSmidth Krebs FMC Technologies Formsprag Clutch ... MMD Mineral Sizing America,In Modern Welding Company

Conference: April 28 – May 1

Exhibits: April 29 – May 1

Lexington Center

Lexington, KY USA

www.coalprepshow.com

The Only Conference andExhibition Serving the Needs

of the Coal Prep Community

Sponsored by:

A Mining Media Inc. publication

Managed and produced by:

FREE Exhibit Hall admissionwhen you register by March 9th!

CompleteDetails Inside

Premier Partners:

Conference organized by:

1

Top 5 BenefitsYou'll ReceiveFrom Coal Prep...

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5

Top-notch education that willincrease your professional worth

Time and money savingswith this one-stop shop

Innovative ideas and solutionsto better your plant operation

Discover the latest industrytrends and developments

Coal Prep is THE meeting place for the coal preparationcommunity!


Coal Prep 2008

3www.coalprepshow.com

Welcome to the 25th Anniversary of Coal Prep…The Meeting Place for the Entire Community!For 25 years, Coal Prep has been the ONLY conference and exhibition specifically serving the needs of thecoal prep professional. We provide the best education the industry has to offer while introducing a multi-tude of vendors providing equipment and services to help better your plant operations and giving you theopportunity to network with your professional peers.

This is the event for all coal prep professionals including:u Plant Managersu Superintendentsu Engineersu Maintenance Professionalsu Quality Control Professionalsu And many more!

The largest coal prep supermarket that the industry has to offer!You will find coal prep and aggregate processing ideas and opportunities all in one place, at one time, onthe Coal Prep exhibit hall floor. If you are looking for any of these products and services, you’ll want tobrowse and network on the show floor.

u Abrasion/Wear Resistant Materialsu Conveying & Feeding Equipmentu Crushers & Pulverizersu Drilling & Blastingu Dust Suppressionu Electrical Equipment & Suppliesu Loading & Hauling Equipmentu Lubricants & Fluidsu Maintenance & Repairu Measurement & Monitoring Equipment

u Motors & Power Transmissionu Mining Equipmentu Pipes, Valves & Fittingsu Plant Automation Systems & Softwareu Processing Equipment & Washersu Pumps & Air Compressorsu Quality Control/Lab Equipmentu Scales & Load out Equipmentu Screening Equipmentu And Much More!

For detailed exhibiting opportunities, contact Sam Posa, Sales Manager

Phone: 1-800-525-9154 • E-mail: [email protected]

Exhibit Hall HoursTuesday, April 29 ...........................................10:30am-5:00pmWednesday, April 30 ....................................10:00am-5:00pmThursday, May 1.............................................9:00am-12:00pm


Coal Prep Provides the Best Education andNetworking Events That the Industry Has to Offer!

Golf TournamentMonday, April 28Every year we host the exciting annual golf tournament! Invite yourmost important clients to play golf with you - a perfect environmentfor networking and fun. 11:30am check-in; 12:00pm lunch; 1:00pmshotgun start.

Opening Remarks & Keynote AddressTuesday, April 29 • 9:00 am – 10:30 amu Remarks by Donovan Symonds, Retiring Chairman, Norwest

Corporation, and introduction of Incoming President of the CPSA,Mel Laurila, QC, Inc.

u Remarks and Keynote Introduction by Incoming President of theCPSA, Mel Laurila, QC, Inc.

u Keynote Address: Fossil Energy, Clean Coal Technology, andFutureGenThomas A. Sarkus, Division Director, Advanced Energy Initiatives Division,National Energy Technology Laboratory, U.S. Department of EnergyThis presentation will provide background information on the rolesof energy, fossil energy (including coal), and electricity in our mod-ern society. Clean Coal Technologies will be discussed in terms oftheir relative states of development and performance attributes.Major research, development and demonstration initiatives of theU.S. Department of Energy will be summarized, with emphasis onenvironmental acceptability.

u Introduction of William Kalb, Chairman of the InternationalOrganizing Committee of the ICPC by Mel Laurila, QC Inc.

u Introduction of the International Organizing Committeeby William Kalb, TraDet, Inc.

u Introduction of Doug Jenkinson of the ICPCby William Kalb, TraDet, Inc.

u The Role of the ICPC in Coal PreparationDoug Jenkinson, Chairman Emeritus of the ICPC

Education andSpecial Events

Education Overview and Special Events


Cocktail ReceptionTuesday, April 29 • 5:00pm – 6:00pmLet’s celebrate our 25th anniversary together! Enjoy a cocktail andsome food while networking with colleagues in a fun and relaxedenvironment. Catch up with old friends, meet new people andexchange industry ideas.

Cocktail Reception sponsored by:

Symposium: Loading & Transportation of Coal in the 21st CenturyMonday, April 28 • 9:00am – 4:30pmSee page 12 for details.

Workshop: Coal Preparation – Operator GuidelinesMonday, April 28 • 10:00am – 3:00pmSee page 13 for details.

Recertification: Annual Refresher Training forImpoundment Inspection Qualified PersonsTuesday, April 29 • 1:00pm – 5:00pmCoal Waste Impoundment – get your MSHA Recertification at CoalPrep! Providing a convenient way for you to renew your certificationannually. See page 13 for details.

Coal Prep Technical SessionsTuesday, April 29 – Thursday, May 1u Plant Safety & Innovationu Dense Medium Cyclonesu Sequestration & Coal Conversionu Fines Dewateringu Preparation PlantsSee pages 14-20 for details.

Coal Prep issupported bythe following

publications andassociations:

Conference Program Organized byCoal Preparation Society of AmericaWe would like to acknowledge and thank the CoalPreparation Society of America (CPSA) for their support and guidance. CPSA serves as a committed

and vital component in delivering such a valuable conference program. These industry experts continue to assist us in making the Coal Prep event better each year.

A Mining Media Inc. publication

6 www.coalprepshow.com

Featured Exhibitors

Featured Exhibitors

Booth 1604

Booth 1332

Booth 1405

Booth 319

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Booth 924

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Booth 725

Booth 1324

Featured Exhibitors


Booth 1109

Booth 1026

Booth 1225

Booth 605

Booth 1018

Booth 1013

Booth 1507

Phoenix Process EquipmentBooth 1007

Phoenix Scale TechnologiesBooth 1111

Booth 404

Booth 1230

Booth 1717

Booth 431

Booth 520

Taggart GlobalBooth 519

Booth 1319

Booth 1615

Booth 1605

Booth 312

Booth 1027


The Exhibit Hall

The Exhibit HallAAA Sales & EngineeringAFL TelecommunicationsAirgasAirgas WeldingAllmineral, LlcAndritz Separation, Inc.Apex Bulk TechnologiesArgonics, Inc.Atlas Railroad ConstructionB.D.I.Beard Technologies, Inc.Belt Tech Industrial, Inc.Berthold TechnologiesBJM PumpsBortonBrechbuhler Scales, Inc.Buchanan Pump Service & SupplyBucyrus America, Inc.C.B.P. EngineeringCaldwell TanksCarbolineCarr Concrete CorporationCarrier Vibrating Equipment, ICentrifugal & Mechanical IndusCeramX ProductsChatham Steel CorporationChestertonChromium CorporationCiba Corporation

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Food Court

Clark Testing GroupCoal Age MagazineCoal LeaderCoal PeopleCommonwealth Equipment Of the VirginiasConn-Weld Industries, Inc.Continental Conveyor & EquipmeCPSA Cumi Canada, Inc.Daniels Company,TheD'Appolonia EngineeringDecanter Machine Inc.Deister Concentrator, LLCDerrick CorporationDixon Valve & Coupling CompanyDoddridge ControlsDuraline, LlcEmerson Power TransmissionEnduride Canada Usa, Inc.Energy TechnologiesEngart Inc.Engineering Consulting ServiceEriez MagneticsFairmont Supply CompanyFarnham & PfileFFE MineralsFlexcoFLSmidth KrebsFMC Technologies

Formsprag ClutchFreedom IndustriesGardner Paint Services, Inc.Godwin PumpsGoodman Conveyor CompanyGrindex PumpsGundlach Equipment CorporationHausner Hard-Chrome, Inc.HD Supply WaterworksHead Equipment, Inc.Headwaters Energy ServicesHein, Lehmann Us, LlcHilliard CorporationHolden Machine & FabricationImperial TechnologiesIndustrial CompositesIndustrial Galvanizers AmericaIndustrial Resources, Inc.Industrial Silo Source, Inc.Inpro/Seal CompanyInterClean Equipment, Inc.ITT Goulds PumpsJabo Supply CorporationJadco, Inc.James A. Redding CompanyJBL, Co.Jeffrey Specialty Systems Johnson Industries, Inc.Johnson Screens

List as of 2-5-08

The Exhibit Hall


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Joy Mining MachineryJVI Vibratory EquipmentK & K Mine ProductsKanawha Manufacturing Co.Kanawha Scales & SystemsKCTS-Kentucky Coal AcademyKentucky Coal AssociationThe Kerry CompanyLaroxLawson Products/Ct EngineeringLincoln Contracting & Equip. CLinatex Corporate of AmLudowici InnovativeMarietta Silos LLCMarshall Miller & AssociatesMartin EngineeringMatrix Design GroupMetso MineralsMclanahan CorporationMinet Lacing TechnologyMMD Mineral Sizing America, InModern Welding Company Of KentMole Master Services CorporatiNalco CompanyNational Mining Association North American Quarry NewsOptical Cable CorporationOTP- Air TechnologiesPartsmasterPennsylvania Crusher CorporationPeters Equipment Co., LlcPhoenix Process Equipment CompPhoenix Scale Technologies

Pipe Products Inc, A Ferguson EnterprisePipestar International, Inc.Pneumat SystemsPolydeck Screen CorpPowell Construction CompanyPower TechniquesPrecision Pulley & IdlerPrecision SamplersPrecismeca LimitedPrep Tech, Inc.Primrose Oil CompanyPumpaction CorporationRaco International, L.P.Ready Technologies, Inc.Reiss VikingRichwood IndustriesRiver ConsultingRoberts & Schaefer CompanyRoche Mining (Mt) Usa, Inc.Rock ProductsS & S Urethane, Inc.SABIA, Inc.San-Con Industries, Inc.Sandvik Mining & ConstructionScantechSchenck Process AmericaSchur Pump CompanySecurity Locknut, Inc.SEI Engineers, Inc.Service Pump & Supply, Inc.SEW-Eurodrive, Inc.SGS Minerals ServicesSmith Services Inc.

SNF Flomin MiningState Electric Supply Co.Steinert Sturton-Gill Magnetics Superior IndustriesTabor Machine CompanyTaggart GlobalTangshan Shenzhou Machinery CoTanner Industries, Inc.Tech MetalsTema Insenmann, Inc.Tema Systems, Inc.Ten Cate GeotubesThe Snell GroupThermo ScientificThompson PumpThor Global EnterprisesToshibaTricon Metals & Services, Inc.Tuff Toe, Inc.Van Der Graaf Inc.Victaulic CompanyW.K. Merriman, Inc.Wainwright FabricatorsWear - ConceptsWeir Slurry Group, Inc.WesTech Engineering, Inc.Whayne Supply Co.World CoalWorthington Products LlcZinkan Enterprises, Inc.


Schedule-at-a-Glance

Schedule-at-a-GlanceMonday, April 28

8:00 am – 5:00pm Attendee Registration Open

9:00 am – 4:30 pm Symposium: Loading & Transportation of Coal in the 21st Century

10:00 am – 3:00 pm Workshop: Coal Preparation - Operator Guidelines

11:30 am Golf Tournament – Check-in at Marriott’s Griffin Gate

Tuesday, April 29

8:00 am – 5:00 pm Attendee Registration Open

9:00 am – 10:30 am Opening Remarks & Keynote Address:

Fossil Energy, Clean Coal Technology, and FutureGen

10:30 am – 5:00 pm Exhibit Hall Open

1:00 pm – 5:00 pm Recertification: Annual Refresher Training for Impoundment Inspection

Qualified Persons

2:00 pm – 4:00 pm u Coal Prep Technical Session I: Plant Safety and Innovation

2:00 pm – 2:30 pm • Innovation in Safety through Modular Design and Construction

2:30 pm – 3:00 pm • Increased Prep Plant Efficiencies Associated with Wireless Inventory

Management Systems

3:00 pm – 3:30 pm • An Application for Mine Safety using GPS Equipment and GIS

Software

3:30 pm – 4:00 pm • Applications of Thermal Sprayed Material

5:00 pm – 6:00 pm Cocktail Reception

Schedule-at-a-Glance


Wednesday, April 30



9:00 am – 11:00 am Two Concurrent Sessions:

9:00 am – 11:00 am u Coal Prep Technical Session II: Dense Medium Cyclones

9:00 am – 9:30 am • Considerations on Dense Medium Cyclone Control

9:30 am – 10:00 am • Alternative Materials for Dense Medium Separations

10:00 am – 10:30 am • Evaluation of Dense Medium Cyclone Performance Using Electronic

Density Tracers

10:30 am – 11:00 am • The Conversion of Holden 22 Plant From 1970S “DMC…by Zero” to

21st Century Efficiency

9:00 am – 11:00 am u Coal Prep Technical Session III: Sequestration & Coal Conversion

9:00 am – 9:30 am • Coal Conversion Technology at Siemens

9:30 am – 10:00 am • The US Department of Energy Coal Conversion Projects

10:00 am – 10:30 am • Current Status of Carbon Capture and Storage (CCS) – Sequestration

10:30 am – 11:00 am • Coal Industry Projects with Gasification

2:00 pm – 4:00 pm u Coal Prep Technical Session IV: Fines Dewatering

2:00 pm – 2:30 pm • Modern Dewatering Technologies for Coal Dewatering

2:30 pm – 3:00 pm • Operating and Maintenance Guidelines for Screenbowl Centrifuges

3:00 pm – 3:30 pm • An Alternative Method of Tailings Disposal at UK Coal Welbeck

Colliery: Utilizing Ciba RHEOMAX ETD Technology

3:30 pm – 4:00 pm • Replacement of Belt Presses with a Deep Cone Thickener at Lone

Mountain Processing

Thursday, May 1



9:00 am – 11:00 am u Coal Prep Technical Session V: Preparation Plants

9:00 am – 9:30 am • Peabody Energy’s Twentymile Coal Mine Builds New Preparation Plant

9:30 am – 10:00 am • Cleaning of -0.6mm High-Ash Metallurgical Coal at Coal Mountain

Operations

10:00 am – 10:30 am • Elk Valley Coal Corporation Implements Smart Cell Flotation

Technology

10:30 am – 11:00 am • Evaluation of Circuit Performance at the Eckman Preparation Plant


Special Sessions

Monday, April 28

9:00 am – 4:30 pm

Symposium: Loading & Transportation of Coal in the 21st CenturyThe intent of this symposium is to review the historical development of high capacity bulk load-out systems, provide a view of current issues in train movements and provide a predictive look at future developments.

9:00 am – 9:30 amu Introduction of Program

Organizer: Bill McHale, Vice President, Kanawha Scales & Systemsu Review of Loadout Systems

• Types of Systems Used in Train Loading Operations• Why Use a Batch Weigh System• From an Eastern Coal Fields Perspective• From a Western Coal Fields Perspective

9:30 am – 10:15 amu Important Issues in Scheduling and Managing Unit Train Movements and How Optimizing

Loading Efficiencies Contributes To Everyone’s Bottom LineSteve Crum, Manager of Coal Development, CSX Railroad

10:15 am – 10:30 am • Break

10:30 am – 11:45 amu Development and Implementation of Enhancements to Norfolk Southern’s Proprietary Coal

Transportation Management System (“CTMS”) Neal Bates, Manager of Information Systems, Norfolk Southern Corporation

11:45 am – 12:00 pmu Questions for the CSX and Norfolk Southern Railroad’s Regarding Coal Transportation Issues

Steve Crum, Manager of Coal Development, CSX Railroad Neal Bates, Manager of Information Systems, Norfolk Southern Corporation

12:00 pm – 1:00 pm • Lunch

1:00 pm – 2:30 pmu Reporting and Integration of Coal Quality Lab Data, Sampling Operation and Performance; and

Analyzer Systems with the Train Loading Operations Paul Reagan, President, SAIAllan Seaman, Standard Laboratories

2:30 pm – 2:45 pm • Break

2:45 pm – 4:30 pmu Continuing Evolution of Train Loadout Systems

Duane Bennett, Sir Systems Analyst, KSS• Unlocking the Power of Automatic Car Identification (AEI Systems)• Totally Unattended/Automatic Loading • Precision Loading at 10,000 to 12,000 TPH Loading Rates• Integration of Train Speed Monitoring with Reclaim Controls Systems in the Loading Operation• Real Time Blending• SCADA Systems • Remote Monitoring and Reporting of Loading Operations via Web Browser

Special Sessions

Special Sessions


10:00 am – 3:00 pm

Workshop: Coal Preparation – Operator GuidelinesA series of successful workshops have been presented at the annual Coal Preparation over the past severalyears to assist coal plant operators and industrial professionals in improving the understanding of the basicprinciples and methods of evaluating unit and overall performances. The workshop will focus on guidelinesfor operating coal preparation plants and process units. The workshop will address:

• Unit operations under typical conditions• Common operational problems• Methods to detect less apparent problems that affect performance and • Solutions as well as possible prevention steps for the common problems.

Industrial experts covering the various areas of a coal preparation plant operation will serve as the instructors for the workshop:u Introduction • Rick Honaker,Chair & Mining Foundation Distinguished Professor,Department of Mining Engineering,

University of Kentucky and Jerry Luttrell,A.T.Massey Professor of Mining & Minerals Engineering,Virginia Techu Coal Cleaning/Sieving • Marvin Woodie, VP Field Operations, Conn-Weld Industries, Inc.u Dense Medium Separators • Robert Moorhead, Senior Process Engineer, Krebs Engineersu Water-Based Separators • Barbara Arnold, President, PrepTech, Inc.u Froth Flotation • Dr. Jaisen N. Kohmuench, Manager, Process Group for R&D, Eriez Manufacturingu Dewatering • Wally Schultz, Decanter Machine, Inc.u Thickening • Dusty Hayhurst, Product Manager, Freedom Industries, Inc.

Tuesday, April 29

1:00 pm – 5:00 pm

Annual Refresher Training for Impoundment Inspection Qualified Persons Ryan O’Boyle and Lyndon Skaggs of MSHA District 7This course provides the 4-hour annual retraining requirements for Qualified ImpoundmentInspectors (QII). Only individuals who have successfully completed the Initial ImpoundmentInspection Qualified Persons training should attend. Individuals who have successfully completed the Initial Impoundment Inspection Qualified Persons training, but have not completed annual retraining in over one year are no longer considered to be a QII. For those individuals to again be considered to be a QII, they must take the 4-hour annual retraining and then pass an examination to successfully complete the course.Topics to be covered during the course are as follows:

• Identifying Signs of Distress & Hazardous Conditions • Basic Instrumentation • Construction Specifications • Construction Best Practices • Question & Answer Session

Opening Remarks & Keynote AddressTuesday, April 29 • 9:00 am – 10:30 amu Remarks by Donovan Symonds, Retiring Chairman, Norwest Corporation, and introduction of

Incoming President of the CPSA, Mel Laurila, QC, Inc.u Remarks and Keynote Introduction by Incoming President of the CPSA, Mel Laurila, QC, Inc.u Keynote Address: Fossil Energy, Clean Coal Technology, and FutureGen

Thomas A. Sarkus, Division Director, Advanced Energy Initiatives Division, National Energy TechnologyLaboratory, U.S. Department of Energy

This presentation will provide background information on the roles of energy, fossil energy (including coal), and electricity in our modern society. Clean Coal Technologies will be discussed interms of their relative states of development and performance attributes. Major research, developmentand demonstration initiatives of the U.S. Department of Energy will be summarized, with emphasis onenvironmental acceptability.

Tom Sarkus is the Division Director for DOE’s FutureGen Initiative, which aims to prove the near-zeroemissions concept for coal-based power plants. Previously, he was a key manager for commercial-scaledemonstration projects, under DOE’s Clean Coal Power Initiative and its predecessor programs. Withover 25 years of relevant technical experience, Tom is well versed in coal preparation, combustion,gasification, and flue gas cleanup technologies.

u Introduction of William Kalb, Chairman of the International Organizing Committee of the ICPCby Mel Laurila, QC Inc.

u Introduction of the International Organizing Committee by William Kalb, TraDet, Inc.u Introduction of Doug Jenkinson of the ICPC by William Kalb, TraDet, Inc.u The Role of the ICPC in Coal Preparation

Doug Jenkinson, Chairman Emeritus of the ICPC

Includedwith all

RegistrationOptions


Technical Program: Tuesday

Technical ProgramTuesday, April 29

2:00 pm – 2:30 pm

u Innovation in Safety through Modular Design and ConstructionGrant Fraser, Thiess Sedgman

This paper examines the impacts of utilizing a modular construction model to construct a CoalPreparation and Handling Plant in New South Wales, Australia for Peabody Energy. The individual floorswere constructed and fitted out at ground level then lifted into place using a single heavy lift crawlercrane. The paper examines the process from a design, constructability, safety and risk management per-spective. The use of a single crane only in the work area assisted in maintaining an uncluttered workenvironment and enabled easy access for elevated work platforms to be used in bolting up and tension-ing of the Coal Preparation Plant structural modules. The lack of uncontrolled work at heights outside ofbarriers and work platforms was eliminated and this ensured that the work force doing the final fit outdid so in a safe environment.

2:30 pm – 3:00 pm

u Increased Prep Plant Efficiencies Associated with Wireless InventoryManagement SystemsJoshua Herzing - Freedom IndustriesGordon Gump - American Coal Company, Galatia PlantThe purpose of this presentation and technical paper is to show the numerous benefits associated withthe implementation of wireless inventory management (WIM) systems in and around preparationplants. WIM Systems can be used to in a number of ways in an around the Preparation Plant to makeoperations run smoother and more efficient.

In the plant WIM's can be used to track polymer, flotation reagent and collector usage providing the fol-lowing benefits:

• The ability to track spikes in usage rates and helping to determine the cause• Accurate Real Time Cost Per Ton Analysis• What application rate combinations help achieve increased fines recovery• Automatic Product Reordering - Eliminate the chance of running out of chemicals• Increased Safety - due to not having to stick tanks• Accurate and Efficient Inventory Management -Real Time Inventory

WIM systems can help to make loadouts run more efficiently in the winter as well. WIM systems providethe following benefits during Freeze Conditioning Season as well.

• Accurate Inventory Rates for FCA and SRA• Ability to setup automatic order generation• Delivery Confirmations• Application Rate Tracking for Customers• Usage Tracking for Accurate Billing• Elimination of holding a train to wait on chemicals• More Efficient Forecasting for Trains

This presentation will outline the details of how WIM systems work, the different kinds available to theindustry and how they benefit the coal producer. Through test work and the tracking of data this pres-entation hopes to educate the audience on ways to make any plant run more efficient, productive andprofitable than before WIM's.

u Session I: Plant Safety and InnovationChair: Dan Yanchak, CONSOL Energy

Technical Program: Tuesday/Wednesday


3:00 pm – 3:30 pm

u An Application for Mine Safety using GPS Equipment and GIS SoftwareEric Muncy, Regional Manager, MapSyncThis presentation explores the application of GPS and ESRI’s ArcPAD software to facilitate mine safety.Coal mine stockpiles present several hazardous conditions and in fact can be fatal if safety measures arenot taken. When coal is drawn from a stockpile, occasionally a void will be created. On the surface ofthe stockpile everything appears normal, but the weight and vibrations from equipment operatingabove the void, or miners walking on the surge pile above the void, could cause it to collapse – poten-tially trapping the dozer and driver in the void.

The purpose of the customized application is to alert the vehicle operator when nearing the stockpilethereby avoiding the hazards associated with it. The application uses ESRI ArcPad software for GPS posi-tioning and the customized application was built using ArcPad Application Builder software. TrimbleGPS units will be used on the operating vehicles. This presentation demonstrates the power of GPS andGIS integration for mine safety applications.

3:30 pm – 4:00 pm

u Applications of Thermal Sprayed MaterialDavid Jewell, Solid Spray, LLCThermal spray is an efficient and cost effective way to apply abrasion and corrosion resistant materialsto metal parts. Thermal sprayed materials offer an alternative to ceramics, polyurethane, hard facingwelding rod, and hard chrome. The application process is quick and safe with no environmental con-cerns.

This presentation will introduce thermal spray methods and discuss several applications where coatingswould be advantageous to the mining industry. Mostly, tungsten carbide is used, but there are manyother materials available commercially on the market with their advantages and disadvantages.Materials must be selected based on the operating temperature and environment where the coatingwill be in service.

There are many benefits to the user that are not available from other wear protection methods.Additionally, thermal spray can be used to repair damaged parts instead of purchasing new ones.

Two case studies will be presented where thermally sprayed coatings have increased the lives of parts.First, stainless steel coatings make pipelines in Russian oil fields last more than 10 times longer. Second,tungsten carbide coatings make centrifugal fan impellers in tobacco processing plants last more than 4times longer. The discussion will conclude with a comparison of the cost of using a thermal spray coat-ing versus using no protection or inferior protection.

Wednesday, April 30

9:00 am – 9:30 am

u Considerations on Dense Medium Cyclone ControlB.A. FIRTH, CSIRO Energy TechnologyDense medium cyclones clean the majority of the run of mine coal in Australia and in many other coun-tries. The current management of these circuits is based on the measurement of medium density andpressure. This paper will discuss the relationships between the controlling factors in this circuit and theperformance factors, relative density of separation and Ep. These relationships have been developedfrom the analysis of over 20 data sets on modern large cyclones in which important factors such asoverflow and underflow densities, feed solids flow rate, medium to coal ratio and loading to the spigotwere recorded. The types of measurements and the level of accuracy to be effective for management ofthis key circuit in a coal preparation plant will then be considered with illustrative examples.

u Session II: Dense Medium CyclonesChair: Joe Andrusiak, Superintendent, Processing, Elk Valley Coal Corporation


Technical Program: Wednesday

9:30 am – 10:00 am

u Alternative Materials for Dense Medium SeparationsRick Honaker, University of Kentucky, Chair & Mining Foundation Distinguished Professor, Department ofMining EngineeringDense medium processes, which are used to clean approximately 65% of the total processed coal in theU. S., employ ultrafine magnetite suspensions to separate the coal from the mineral matter. Due torecent market events, magnetite costs have nearly tripled which has driven the U. S. coal industry costsupward to approximately $42 million annually. Alternative materials have been evaluated as a replace-ment for magnetite in a dense medium cyclone. These materials include steel manufacturing waste,magnetic material from coal combustion bottom ash material, fine sand and the 65 x 325 mesh fractionobtained from coal waste as well as alternative sources of low cost magnetite.

The tests were performed on the 1/4-inch x 28 mesh particle size fraction of run-of-mine Coalberg seamcoal using a 6-inch diameter dense medium cyclone (DMC). Relative medium density values over arange of 1.3RD to 1.7RD were evaluated under feed pressure values from 2.5 to 10 psi. The high end ofthe feed pressure range provided centrifugal forces that are significantly greater than those realized inindustrial DMC units, which provided a good assessment of the stability characteristics of the eachmedium type. The medium-to-coal ratio was maintained at 4:1 during the entire test program. Theresponse variables that were monitored include the probable error value, density offset, and the quanti-ties of by-pass material, organic efficiency and the medium density differential between the underflowand overflow streams.

Under certain conditions, each of the materials tested provided separation efficiencies that meet indus-trial standards including probable error values of around 0.03. The nominal 65 x 325 mesh materialobtained from the spiral refuse screen overflow in an operating plant achieved excellent organic effi-ciency values exceeding the 95% level over a medium density range from 1.3RD to 1.6RD with lowerthan normal density offsets. Similar performances were achieved using the steel slag waste and sandbut at density value below 1.5RD. The low cost magnetite was significantly coarser than the typicalindustrial standard and thus provided separation efficiencies that improved and surpassed thoseobtained from conventional magnetite with an increase in medium density. The results from the studywill be presented and discussed in this publication.

10:00 am – 10:30 am

u Evaluation of Dense Medium Cyclone Performance Using ElectronicDensity TracersChris Barbee, Sr. Coal Processing Engineer, Arch Coal Inc.Density tracers are a useful diagnostic tool for evaluating the separation efficiency of dense mediumcyclones. Unfortunately, the full capabilities of density tracers are often not realized in industrial practicedue to large losses that occur during the manual retrieval of the density tracers from drain and rinsescreens. To overcome this problem, a low-cost electronic monitoring system has been developed to auto-matically identify and count the tracers as they pass through a coal cleaning circuit. This technique, whichrelies on recent technological breakthroughs in transponder technology, improves the reliability of tracerdata by eliminating statistical errors associated with lost tracers. In addition, this simple system makes itpossible for efficiency tests to be performed very rapidly by a single person. Field tests conducted using aprototype system showed that very accurate counts (>98%) of the transponder-based tracers could beachieved in full-scale trials at an industrial plant. This article describes how to construct the system andhow it can be used to trouble-shoot common problems in dense medium cyclone circuits.

10:30 am – 11:00 am

u The Conversion of Holden 22 Plant From 1970S “DMC…by Zero” to 21stCentury Efficiency Peter Bethell, Director of Preparation, Arch CoalThe paper will review the old circuitry: plus 3/4" material to a dense medium vessel, with minus 3/4" by zeromaterial to dense medium cyclones.The original plant had seven double drum magnetic separators, on bothclean and refuse dilute circuits. Effluent from clean coal sieving of the clean coal magnetic separator tailings,coupled with refuse magnetic separator tails, and fine coal dryer effluent all passed to the refuse thickener.Major coal losses were occurring in+100 mesh material in the thickener. Also impoundment life was beingseverely reduced by this material. After much consideration a de-slime dense medium cyclone circuit wasdeveloped re-using existing raw coal and pre-wet screens.The four original dense medium cyclones werereplaced with a single 33" unit. A compound spiral circuit, clean coal cyclone circuit and refuse cyclone circuitwere also added.The performance of the old plant and the upgraded facility will be reviewed.



9:00 am – 9:30 am

u Coal Conversion Technology at SiemensHarry Morehead, Manager, IGCC Business Development, Siemens Power Generation, Inc.Siemens provides a range of clean coal based power generation options including supercritical andultra-supercritical steam plants and IGCC plants. With the recent acquisition of the Siemens SFG gasifi-cation technology, Siemens is offers gasification technology for a range of applications including IGCC,coal to chemicals and coal to liquids projects. This presentation will first provide overview of theSiemens SFG technology and an update of the Siemens gasification activities including a review of cur-rent projects in North American and China. The presentation will conclude with an overview of the coalpreparation requirements for the Siemens technology for a range of coals.

9:30 am – 10:00 am

u The US Department of Energy Coal Conversion Projects Thomas A. Sarkus, Division Director, Advanced Energy Initiatives Division, National Energy TechnologyLaboratory, U.S. Department of EnergyThis presentation will provide background information on the roles of energy, fossil energy (coal), andelectricity in our modern society. Clean Coal Technologies will be discussed in terms of their relativestates of development and performance attributes.

10:00 am – 10:30 am

u Current Status of Carbon Capture and Storage (CCS) – SequestrationEduardo J. Manrique, Ph.D., Sr. Reservoir Engineer, Norwest Questa EngineeringDespite significant progress made with CO2 capture and sequestration (CCS) technologies throughout2007, certain economic variables including a lack of legal and regulatory framework continue to poseserious impediments in making CCS a more viable emission reduction strategy.

Capturing CO2 from emission sources is a key logistical consideration for most CCS projects. That said,existing commercial CCS technologies are energy-intensive and costly, making capture and sequestra-tion complicated. However over the last year, newer and more advanced technologies have been intro-duced that claim CO2 can be captured by as much as 95% from flue gases and at much lower costs (<$30/Ton) and by using less energy (expending only 10% versus 30% of total power plant output).Examples of such newer technologies include the chilled ammonia process (CAP) and Sargas capture.These technologies are still being fine-tuned and are slated to become commercially available between2010 –2012. The CAP and Sargas capture technologies represent just two of many ongoing case-studyefforts to develop low cost, reduced energy-intensive CO2 capture technologies. One such example isthe recent announcement of the DECARBit project which is a 4-year R&D initiative funded by theEuropean Union for the development of carbon capture technologies of coal and gas-fired powerplants.

Current trends are still being defined in regards to existing international CCS projects. And despite sev-eral new CCS initiatives and projects introduced over the last few months, (i.e. RWEnpower CO2 capturepilot plant at Aberthaw Power Station in UK; NRG / Powergen’s 125 MW CCS demonstration plant inTexas; Abu Dhabi $15billion fund for developing clean energy projects and CCS pilot project at DeltaElectricity's Munmorah power station in Australia, including three large DOE projects), a number of proj-ects are being cancelled or delayed for various reasons. Examples of such on-hold/ terminated projectsinclude the following:

• Coal-fired power plant (Sunflower Electric Power) permit revoked due to CO2 emissions by theKansas Department of Health and Environment.

• Energy Northwest coal-fired power plant permit was revoked in Washington State due to incompli-ance with CCS issues.

• PacificCorp cancelled a coal gasification CCS demonstration project in Wyoming due to the level ofuncertainties associated with climate change regulations and high costs.

• Tampa Electric deferred use of IGCC beyond 2013 due to uncertainties related to CO2 regulationsand CCS cost increases

10:30 am – 11:00 am

u Coal Industry Projects with Gasification

u Session III: Sequestration & Coal RemovalChair: Bill Kalb, TraDet, Inc.



2:00 pm – 2:30 pm

u Modern Dewatering Technologies for Coal DewateringJaakko-Juhani Helsto, Manager – Coal Business, Larox CorporationGuido Goerres, Business Manager – Bulk Mining, Larox GmbHLarox develops, designs, and manufactures industrial filters and is a leading technology company in itsfield. Companies in mining and metallurgy, chemical processing elated industries benefit from our high-performance, high-efficiency process solutions, technologies, and products.

As the demand for coal grows producers will have to look for higher productivity in their operations.Safety, maintenance, environmental conditions, and water recovery are the key words in the future.

This means the existing operations have to be analyzed based on those demands. The industry is forcedto develop new and more efficient processes including new machines to process coal in amore efficientway. Thus this paper will focus on the comparison mainly between well-established dewatering tech-nologies like belt presses and capillary action filters as the Larox Ceramec technology.

Pre-feasibility studies based on this technology show tendencies to decrease power consumption, lowermaintenance costs as well as decrease the use of flocculants. On the other hand a high level of recoveryof process water is possible. This will lead to review the flow sheets for coal dewatering in coal wash-eries to increase the efficiency of the plants.

Also the technology of capillary action filters was introduced into the market already in the l980’s, therecent development of plate technology promises better capacities as compared to studies undertakenin the l990’s in the US.

Based on the better understanding of coal dewatering and the mechanism of coal theology, the per-formance of big units can be optimized for high capacity production.

2:30 pm – 3:00 pm

u Operating and Maintenance Guidelines for Screenbowl CentrifugesPresenters: Ron Jahnig, Coal Processing Engineer, Decanter Machine, Inc.Wally Schultz, Executive Vice President, Decanter Machine, Inc.Robert Bratton, Department of Mining and Minerals Engineering, Virginia TechGerald Luttrell, Department of Mining and Minerals Engineering, Virginia Tech.The most popular unit operation for dewatering fine coal in the U.S. is the screen-bowl centrifuge. Thepopularity of this industry workhorse is largely due to the high reliability of this unit and the ability ofscreen-bowl centrifuges to provide lower overall moistures than vacuum filters. This article describes theworking features of screen-bowl centrifuges and discusses some of the common problems that may beencountered in industrial operations. Operating and maintenance recommendations are also providedthat can be used to ensure plant dewatering circuits equipped with screen-bowl centrifuges are welldesigned and properly operated.

u Session IV: Fines DewateringChair: Mel Laurila, President, Quality Control, Inc.



3:00 pm – 3:30 pm

u An Alternative Method of Tailings Disposal at UK Coal Welbeck Colliery:Utilizing Ciba RHEOMAX ETD TechnologyJonathan Brough, Group Coal Preparation Engineer, UK Coal, United KingdomIan Flanagan, Business Development Manager, Ciba PLC, United Kingdom Welbeck Colliery is nearing the end of its planned life. Planning consent has been obtained for exten-sions to the spoil heap twice in recent years and, further extensions are unlikely to be obtainable. Atpresent there is probably enough capacity left to raise the disposal area to its approved contours, but atleast 80% of the remaining capacity is theoretical in so far as the volume is above the current active tail-ings lagoon.

UK Coal Welbeck Colliery has tested a range of Ciba Rheology modifiers. These products are added at acontrolled dosage in-line into the thickened tailings at a point determined through laboratory and planttrials, but usually close to the final discharge pipe or launder. These products modify the surface proper-ties of the tailings when added to the slurry producing a high yield stress material with controllablestacking and rapid water release and recovery. The resulting rigidified tailings can then be over cappedwith coarse discard. The application, known as Ciba RHEOMAX ETD technology has been investigated inthe laboratory and at Welbeck Colliery in a trial cell. Following the success of these tests and trials thetechnology has now been implemented on a full size disposal cell.

3:30 pm – 4:00 pm

u Replacement of Belt Presses with a Deep Cone Thickener at LoneMountain ProcessingB.K. Gupta, Plant Manager, Lone MountainRoy Gross, Plant Supt., Lone Mountain ProcessingPeter Bethell, Director of Coal Preparation, Arch CoalDue to an impoundment leak in 1997 it was decided to reduce the amount of water sent to the finerefuse impoundment. The technology available at the time was the belt press that dewatered the thick-ener underflow to 50% solids so that it could be hauled to the impoundment. The belt presses aremaintenance intensive and have high chemical consumption rates. For these reasons it was decided toreplace the belt presses with a deep cone thickener (DCT). This paper will outline the justification andinstallation of the unit. It will also present important points in the start-up and optimization of the deepcone thickener operation. Finally it will recount the benefits of the transition from belt presses to DCT.


Technical Program: Thursday

Thursday, May 1

9:00 am – 9:30 am

u Peabody Energy’s Twentymile Coal Mine Builds New Preparation PlantP.G. Davis, S.T. Bushart, and M.C. Tackett, Peabody EnergyIn 2007, Twentymile Coal Mine added a new 1400 ton per hour coal preparation plant to be able to pro-vide an enhanced product quality. Changes in seam geology and tonnage requirements prompted thisaddition from the historic production quality and capabilities of the existing 300 ton per hour facility.The new state-of-the-art plant will be able to market a wide range of product qualities by utilizing scalp-ing screens and a by-pass system to partially wash the coarse coal only or by fully washing the run-of-mine feed.

This paper will discuss the engineering and construction phases of the project as well as current infor-mation on plant performance. Information will also be presented on some of the design features of theplant along with equipment selection and plant capabilities.

9:30 am – 10:00 am

u Cleaning of -0.6mm High-Ash Metallurgical Coal at Coal MountainOperationsDaniel A. Desrosiers, P.Eng., Process Engineer, Elk Valley Coal Corporation, Coal Mountain OperationsElk Valley Coal Corporation’s Coal Mountain mine near Sparwood, British Columbia produces exportmetallurgical coal containing about 12% ash content. The washability of this coal differs significantlyfrom surrounding coal deposits in the region that can typically be cleaned to less than 10% ash. A sin-gle-stage water-only cyclone (WOC) circuit does not result in adequate cleaning or recovery of the fine(-0.6mm) coal. Spirals are consequently used to re-treat the WOC underflow. WOC overflow is sized inclassifying cyclones, with 0.60x0.25mm material reporting to the final product and 0.25x0mm materialre-treated by flotation. This paper describes the relationship between these 3 fine coal cleaning meth-ods. It considers their effect on total plant yield and product ash with an emphasis on each method’sincremental ash content.

10:00 am – 10:30 am

u Elk Valley Coal Corporation Implements Smart Cell Flotation TechnologyChris Stirling, Senior Processing Engineer, Elk Valley Coal CorporationIn anticipation of future raw coal containing higher fines content the Elk Valley Coal CorporationGreenhills Operations upgraded their fines circuit to include Wemco Smart flotation cells. The eight15m3 cells were commissioned in March 2007. The cells were installed as two parallel banks of four cellsand are used as rougher cells in a rougher/scavenger arrangement with the previously existing cells.Upon starting the plant up the flotation tailings were visibly cleaner. Lab results confirmed that theflotation tailings ash had increased by 20%. With this increase in yield the Smart cells project paid foritself in less than 5 months, and will contribute to our bottom line into the future with the added benefitof extending our tailings pond life.

10:30 am – 11:00 am

u Evaluation of Circuit Performance at the Eckman Preparation PlantLarry A. Watters, Richard L. McCormick, and Andy Dynys, Taggart Global, LLCGreg Jesse, Mid-Vol Leasing, Inc.Taggart Global, LLC recently commissioned the Eckman Preparation Plant for Mid-Vol Leasing, Inc. on aBuild-Operate-Maintain (BOM) basis. The plant, located outside Princeton, WV, processes Pocahontas 6seam coal to produce a high quality metallurgical product. Plant circuitry includes a Heavy MediaCyclone, Water-Only Cyclone/Spiral and Ultrafine Spirals.

Taggart has conducted an extensive sampling and analysis program to optimize the efficiency and cleancoal yield of the plant while maintaining a consistent clean coal quality. This article will focus on thecoal quality and the efficiency of the equipment/circuits installed.

u Session V: Preparation PlantsChair: Bob Hollis, Vice President Preparation, James River Coal

Speakers


SpeakersAndrusiak, JoeSuperintendent, Processing, Elk Valley CoalCorporation• Session II: Dense Medium Cyclones

Arnold, Barbara President, PrepTech• Workshop: Coal Preparation - Operator

Guidelines

Barbee, ChrisSr. Coal Processing Engineer, Arch Coal, Inc.• Session II: Dense Medium Cyclones

Bates, NealManager of Information Systems, NorfolkSouthern Corporation• Symposium: Loading & Transportation of

Coal in the 21st Century

Bennett, DuaneSenior Systems Analyst, KSS• Symposium: Loading & Transportation of


Bethell, PeterDirector of Preparation, Arch Coal, Inc.• Session II: Dense Medium Cyclones• Session IV: Fines Dewatering

Bratton, RobertDepartment of Mining and MineralsEngineering, Virginia Tech• Session IV: Fines Dewatering

Brough, JonathanGroup Coal Preparation Engineer, UK Coal• Session IV: Fines Dewatering

Crum, SteveManager of Coal Development, CSXRailroad • Symposium: Loading & Transportation of


Davis, Philip G.Director of Coal Preparation Support &Quality Control, Peabody Energy• Session V: Preparation Plants

Desrosiers, DanielSenior Process Engineer, Elk Valley CoalCorporation• Session V: Preparation Plants

Dynys, AndyTaggart Global, LLC• Session V: Preparation Plants

Firth, B.A.CSIRO Energy Technology• Session II: Dense Medium Cyclones

Flanagan, IanBusiness Development Manager, Ciba PLC• Session IV: Fines Dewatering

Fraser, GrantManager, Thiess Sedgman Joint Venture• Session I: Plant Safety and Innovation

Goerres, GuidoBusiness Manager-Bulk Mining, Larox GmbH• Session IV: Fines Dewatering

Gross, RoyPlant Supt., Lone Mountain Processing, Inc.• Session IV: Fines Dewatering

Gupta, B.K.Plant Manager, Lone Mountain Processing,Inc.• Session IV: Fines Dewatering

Hayhurst, DustyProduct Manager, Freedom Industries, Inc.• Workshop: Coal Preparation - Operator

Guidelines

Helsto, Jaakko-Juhani Manager – Coal Business, Larox Corporation• Session IV: Fines Dewatering

Herzing, JoshuaDirector Business Development, FreedomIndustries• Session I: Plant Safety and Innovation

Hollis, Robert W.Vice President, Preparation, James RiverCoal Co.• Session V: Preparation Plants

Honaker, Rick Mining Foundation Distinguished Professor,Department of Mining Engineering,University of Kentucky• Workshop: Coal Preparation - Operator

Guidelines• Session II: Dense Medium Cyclones

Jahnig, RonCoal Processing Engineer, DecanterMachine, Inc.• Session IV: Fines Dewatering

Jesse, GregMid-Vol Leasing, Inc.• Session V: Preparation Plants

Jewell, DavidSales Manager, Solid Spray, LLC• Session I: Plant Safety and Innovation

Kalb, G. WilliamTraDet, Inc.• Session III: Sequestration & Coal

Conversion

Kohmuench, JaisenEriez• Workshop: Coal Preparation - Operator

Guidelines

Laurila, MelPresident, Quality Control, Inc.• Session IV: Fines Dewatering

Luttrell, Gerald (Jerry)A.T. Massey Professor of Mining & MineralsEngineering, Virginia Tech• Workshop: Coal Preparation - Operator

Guidelines• Session IV: Fines Dewatering

Manrique, Eduardo Sr. Reservoir Engineer, Norwest QuestaEngineering• Session III: Sequestration & Coal

Conversion

McCormick, RichardTaggart Global, LLC• Session V: Preparation Plants

McHale, BillVice President, Kanawha Scales & Systems• Symposium: Loading & Transportation of


Morehead, BobSenior Process Engineer, Krebs• Workshop: Coal Preparation - Operator

Guidelines

Morehead, HarryManager, IGCC Business Development,Siemens Power Generation, Inc.• Session III: Sequestration & Coal

Conversion

Muncy, Eric Regional Manager, MapSync• Session I: Plant Safety and Innovation

O'Boyle, RyanMSHA, District 7• Annual Refresher Training for

Impoundment Inspection QualifiedPersons

Reagan, PaulPresident, SAI• Symposium: Loading & Transportation of


Sarkus, ThomasDivision Director, Advanced EnergyInitiatives Division, National EnergyTechnology Laboratory, U.S. Department ofEnergy • Keynote Address• Session III: Sequestration & Coal

Conversion

Schultz, WallyExecutive Vice President, Decanter Machine,Inc.• Workshop: Coal Preparation - Operator

Guidelines• Session IV: Fines Dewatering

Seaman, AllanStandard Laboratories• Symposium: Loading & Transportation of


Skaggs, LyndonMSHA, District 7• Annual Refresher Training for

Impoundment Inspection QualifiedPersons

Stirling, ChrisSenior Process Engineer, Elk Valley CoalCorporation• Session V: Preparation Plants

Watters, LarryChairman, Taggart Global, LLC• Session V: Preparation Plants

Woodie, Jr., MarvinVP Field Operations, Conn-Weld IndustriesInc.• Workshop: Coal Preparation - Operator

Guidelines

Yanchak, DanCONSOL Energy• Session I: Plant Safety and Innovation


Coal Prep 2008

General InformationExhibit Hall HoursTuesday, April 29 ...........................................10:30am-5:00pmWednesday, April 30 ....................................10:00am-5:00pmThursday, May 1.............................................9:00am-12:00pm

Registration HoursMonday, April 28 ...........................................8:00am-5:00pmTuesday, April 29 ...........................................8:00am-5:00pmWednesday, April 30 ....................................8:00am-5:00pmThursday, May 1.............................................8:00am-12:00pm

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Platinum Passport (4/28-5/1)Includes admission to all Coal Prep Technical Sessions (Tues. - Thurs.), A Workshop or Symposium onMonday, lunch on Monday and all 3 days of exhibit hall. Please select the Workshop or Symposium you plan on attending and your choice of Conference Proceedings on the registration page.

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Coal Symposium:Loading & Transportation of Coal in the 21st Century: (9am-4:30pm)

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